DMC:V2500-A1-72-41-2000-00A-655A-B|Issue No:004|Issue Date:2020-02-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

V2500-A1

Common Information

TASK 72-41-20-440-006-A02 HPC Rear Cases And Vanes Assembly - Machine The Stage 7 Through 11 Stator Vane Tips And The Stage 7 Through 12 Rotor Path Ring Liners (Mechanical Clamping Tool Method), Assembly-006

General

Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the Service Bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject the applicable Chapter/Section/Subject comes before the Fig/item number.

For standard torque data and procedures refer to SPM TASK 70-41-00-400-501, SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-400-501.

Special torque data and assembly tolerances are included in the procedure.

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS approved engine oil unless other lubricants are referred to in the procedure.

After assembly apply CoMat 07-038 AIR DRYING ENAMEL to any damaged surface protection, joint flanges and parts used to attach. Use the correct color of the air drying enamel. Refer to SPM TASK 70-63-02-380-501.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Refer to Figure for a sectional view of the HP compressor rear cases and vanes.

Make sure all the flange faces and tool faces that touch are very clean.

This TASK gives the procedure to replace the wax encapsulating process.

This TASK gives the procedures to machine the stator vane tips and the rotor path ring liners.

Machining Requirements

The data that follows is a guideline. If any additional data is necessary contact IAE.

For the rotor path ring machining, a machine is necessary that can meet the conditions that follow:

Permits a 31.00 in. (787.4 mm) diameter by 16.00 in. (406.4 mm) depth workpiece to be installed.

The workpiece must be turned in a counterclockwise direction, when viewed from the tailstock.

Permits a K Grade Carbide I.T.T. turning tool with a 0.031 in. (0.79 mm) radius tip to be installed.

The conditions that follow must be used when you machine the rotor path linings:

A component surface speed of 70 m/min. This is equivalent to a speed of 43 r.p.m.

The maximum depth of cut to be used is 0.006 in. (0.15 mm).

The feed rate is to be determined by 'general feel' for the workpiece.

For the stator vane tip grinding, a machine is necessary that can meet the conditions that follow:

Permits a 31.00 in. (787.4 mm) diameter by 16.00 in. (406.4 mm) depth workpiece to be installed.

The workpiece must be turned in a clockwise direction, when viewed from the tailstock.

Permits a grinding set-up to be attached to the machine. It will be necessary for the grinding wheel to be turned.

The grinding wheel must be turned in a counterclockwise direction, when viewed from the tailstock.

Permits a swarf extraction unit to be installed.

The conditions that follow must be used when you are grinding the stator vane tips:

A component surface speed of 34 m/min. This is equivalent to a speed of 23 r.p.m.

A grinding wheel surface speed of 1675 m/min. This is equivalent to a speed of approximately 4090 r.p.m. at the recommended grinding wheel diameter.

A grinding wheel diameter of between 4.6 in. and 5.5 in. (117 mm and 140 mm).

Grind the repair area to the requirements of Figure to Figure. Refer to the SPM for consumables and definition where it is appropriate.

It is recommended that you use a plunge grinding method with an infeed rate of 0.0075 mm per revolution.

Use a 'spark-out' time of 10 revolutions or 25 seconds.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

Name	Manufacturer	Part Number / Identification	Quantity
IAE 1R18212 Support ring	0AM53	IAE 1R18212	1
IAE 1R18321 Turnover stand	0AM53	IAE 1R18321	1
IAE 1R18412 Turning fixture	0AM53	IAE 1R18412	1
IAE 1R18413 Turnover stand adaptor	0AM53	IAE 1R18413	1
IAE 1R18414 Boring bar	0AM53	IAE 1R18414	1
IAE 1R18415 Pallet	0AM53	IAE 1R18415	1
IAE 1R18416 Lifting tool	0AM53	IAE 1R18416	1
IAE 1R18417 Lifting Turnover trunnions	0AM53	IAE 1R18417	2
IAE 1R18418 Multiflex holder	0AM53	IAE 1R18418	1
IAE 1R18419 Probe holder	0AM53	IAE 1R18419	1
IAE 1R18420 Dressing attachment	0AM53	IAE 1R18420	1
IAE 1R18421 Diamond dresser	0AM53	IAE 1R18421	1
IAE 1R18422 Support probe bracket	0AM53	IAE 1R18422	1
IAE 1R18430 Turning holder	0AM53	IAE 1R18430	1
IAE 1R18431 Lifting beam	0AM53	IAE 1R18431	1
IAE 1R18700 Machine drawing	0AM53	IAE 1R18700	1
IAE 1R18760 Grinding head	0AM53	IAE 1R18760	1
IAE 1R18806 Setting piece	0AM53	IAE 1R18806	1
IAE 1R18807 Setting piece	0AM53	IAE 1R18807	1
IAE 1R18808 Setting piece	0AM53	IAE 1R18808	1
IAE 1R18809 Setting piece	0AM53	IAE 1R18809	1
IAE 1R19836 TBD	0AM53	IAE 1R19836	1
IAE 1R19837 TBD	0AM53	IAE 1R19837	1
IAE 3R18232 Lifting beam	0AM53	IAE 3R18232	1
Grinding Machine	LOCAL	Grinding Machine
K Grade I.T.T. Turning Tool	LOCAL	K Grade I.T.T. Turning Tool
Mechanical Brush	LOCAL	Mechanical Brush
Protective Gloves	LOCAL	Protective Gloves
Vacuum	LOCAL	Vacuum	1
Vibration peening equipment	LOCAL	Vibration peening equipment

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
DELETED	LOCAL	DELETED
CoMat 07-038 AIR DRYING ENAMEL	k3504	CoMat 07-038
CoMat 10-077 APPROVED ENGINE OILS	X333X	CoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

1. CAUTION
  MAKE SURE THAT THE TOOL FACES AND COMPONENT FACES THAT TOUCH ARE CLEAN AND ARE NOT DAMAGED. DIRTY OR DAMAGED SURFACES CAN CAUSE INCORRECT INDICATIONS AND CAN DAMAGE COMPONENTS.
  CAUTION
  REPLACE DAMAGED CLAMPING ELEMENTS. DAMAGED CLAMPING ELEMENTS CAN CAUSE DAMAGE TO THE STATOR VANES DURING THE GRINDING PROCEDURE.
  NOTE
  Rotor paths must be machined before fitting the mechanical clamping tools.
  Refer to Figure and Figure.
2. 1. Make sure that the rubber protection faces of the clamping elements (part of the IAE 1R19837 TBD) are clean and free of damage. Damaged rubber protection faces can cause the metal parts of the clamping elements to touch the stator vanes. If the metal parts of the clamping element touch the stator vanes, they can cause damage.
  2. Make sure that the clamping elements are not bent out of shape.
  3. Make sure that the screws (part of IAE 1R19837 TBD) that adjust the clamping elements have been screwed out to the mechanical stops. Do not turn the screws past the mechanical stop.
  4. Replace any damaged clamping elements.
3. 1. Identify each clamping element with its stage number and the top position. The number one span element must be installed after the number two and three clamping elements.
  2. CAUTION
    MAKE SURE THAT THE EYE BOLTS ARE REMOVED FROM THE TOP PLATE AFTER INSTALLATION.
    Put the top plate number 1 equally on the vanes and install.
  3. Install the stage 11 clamps (part of the IAE 1R19837 TBD) below the stage 11 vanes. Install the clamp 1 first, clamp 2 second and then clamp 3 last.
  4. Push the clamps carefully back towards the rotor path.
  5. Use the detachable screw in handles (part of the IAE 1R19837 TBD) for easy loading.
  6. Make sure that the vanes at the split line are adequately covered by the clamps.
  7. Install the clamps for the stages 7 to 10 below the stage 7 to 10 stator vanes.
  8. Do the steps (Step) to (Step) again.
  9. Install the stage 7 to 11 clamps on the stage 7 to 11 stator vanes.
  10. Do the steps (Step) to (Step) again.
  11. NOTE
    Tighten the bolts only sufficient to take the movement out of the clamp by wedges. Stagger the split lines as you go up the case.
    Tighten the bolts lightly with allen key from the bottom to the top of the case.
1. CAUTION
  YOU MUST MAKE SURE THAT THE TOOL FACES AND COMPONENT FACES THAT TOUCH ARE CLEAN AND ARE NOT DAMAGED. DIRTY OR DAMAGED SURFACES CAN CAUSE INCORRECT INDICATIONS AND CAN DAMAGE COMPONENTS.
  CAUTION
  YOU MUST REPLACE DAMAGED CLAMPING ELEMENTS. DAMAGED CLAMPING ELEMENTS CAN CAUSE DAMAGE TO THE STATOR VANES DURING THE GRINDING PROCEDURE.
  CAUTION
  YOU MUST REPLACE CENTRALISING TYRE. DAMAGED TYRE CAN CAUSE DAMAGE TO THE STATOR VANES.
  Refer to Figure, Figure, Figure, Figure and Figure.
2. Install the centralising pillar (part of the IAE 1R19836 TBD) on the draw bar.
3. Install the spider (part of the IAE 1R19836 TBD) on the setting bush for stage 11 with the four arms inward.
4. Move the spider arms outwards.
5. Carefully collapse the centralising ring tyre (part of IAE 1R19836 TBD) after removal of the round up ring (part of the IAE 1R19836 TBD) and insert into case, resting onto the four spider arms.
6. Install the round ring again and record the valve position.
7. WARNING
  DO NOT INFLATE AIR CENTRALISING RING TYRE TO MORE THAN 3.5 BAR (51 PSI). IF YOU PUT TOO MUCH PRESSURE IN THE TYRE, THE TYRE CAN EXPLODE. AN EXPLOSION CAN CAUSE INJURY TO PERSONNEL AND DAMAGE EQUIPMENT.
  Connect the air line and pressure gauge to the tyre of centralising ring and inflate to a maximum pressure of 3.5 bar (51 PSI).
8. Disconnect the air line.
9. Put the four spider arm inwards and carefully remove the spider.
10. Do the steps (Step) to (Step) subsequently for the stages 7 to 10.
11. Remove the centralising pillar.
12. Set the power driver to torque value of 18 lbfin (2 Nm).
13. Tighten the bolts (part of IAE 1R19836 TBD) on the stage 7 clamps with the power driver.
14. Do the steps (Step) and (Step) for stages 8 to 11.
15. Deflate the stage 7 centralising ring tyre to collapse and carefully remove the centralising ring tyre.
16. Keep the centralising ring tyre in the storage carefully.
17. Do the steps (Step) and (Step) for the stages 8 to 11.
18. Remove the power driver.
1. Refer to Figure and Figure.
2. 1. Attach a correct sling and hoist to the turnover stand adapter.
  2. Lift the turnover stand adapter and put it in the turnover stand.
  3. Attach the turnover stand adapter to the turnover stand with the six tool bolts. Use three 0.375 in. (9.50 mm) 24 UNF X 0.750 in. (19.05 mm) long bolts at the position 2. Use the three 0.375 in. (9.50 mm) 24 UNF X 0.50 in. (12.7 mm) long bolts at the position 1.
  4. Tighten the six tool bolts to safety the turnover stand adapter.
3. 1. Attach a correct sling and hoist to the turning fixture.
  2. Lift the turning fixture and put it in position over the turnover stand adapter.
  3. Lower the turning fixture on to the turnover stand adapter. At the same time align the dowel on the turnover stand adapter with the dowel hole in the turning fixture.
  4. Attach the turning fixture to the turnover stand adapter with the four tool bolts. Use the four 0.750 in. (19.05 mm) 10 UNC X 3.00 in. (76.2 mm) long bolts.
  5. Tighten the bolts to safety the turning fixture.
1. Refer to Figure and Figure.
2. 1. Use a correct hoist and lift the lifting tools to the HP compressor rear cases and vanes.
  2. Align the four holes in the lifting tool with four holes in the front support cone HPC Ring Cases And Related Parts (72-41-21,03-300) outer flange. Use the bolt holes that are on each side of a location dowel hole.
  3. Install the four bolts and washers, part of the lifting tool, through the front support cone outer flange. These attach the lifting tool to the front support cone.
  4. Tighten the four bolts.
3. 1. Remove the 10 nuts and 10 washers which attach the 10 clamps to the turning fixture. Remove the 10 clamps.
  2. Release the 24 nuts which attach the 12 location blocks to the turning fixture. Slide the 12 location blocks radially out.
  3. Use a correct hoist attached to the lifting tool and lift the HP compressor rear cases vanes above the turning fixture.
  4. Carefully lower the HP compressor rear cases and vanes in to the turning fixture. Engage the 10 dowels in the turning fixture with the 10 dowel locating holes in the front support cone outer flange. There is a dowel location hole on each of the legs of the lifting tool. These must be located on two of the dowels on the turning fixture.
  5. Align the cross key ring and seal assembly with the 12 locating blocks on the turning fixture.
  6. Install the 10 clamps removed in Step. Tighten the 10 nuts in sequence.
  7. Remove the four bolts and washers which attach lifting tool to the front support cone.
  8. Remove the lifting tool.
4. Turn the HP compressor rear cases and vanes with the turning fixture from the vertical position to the horizontal position.
1. Refer to Figure.
2. 1. Remove the four bolts from the front face of the lifting beam.
  2. Use a correct hoist and lift the lifting beam on to the turning fixture. Align the lifting beam front face with the location on the turning fixture.
  3. Install the four bolts removed in step Step.
  4. Tighten the four bolts.
3. 1. Adjust the hoist used in step Step until it just holds the weight of the turning fixture and the HP compressor rear cases and vanes.
  2. Remove the four bolts and washers which attach the turning fixture to the turnover stand adapter.
  3. Use the hoist and remove the turning fixture with the HP compressor rear cases and vanes from the turnover stand adapter. Carefully lower the assembly in to the IAE 1R18415 Pallet 1 off.
4. Transport the assembly to the machine area to have the stator vanes and rotor path rings machined.
1. Refer to Figure and Figure.
2. Attach the IAE 1R18760 Grinding head 1 off to the machine. Use a correct adapter plate.
3. 1. Attach the IAE 1R18420 Dressing attachment 1 off to the grind attachment on the machine and safety with the four set screws.
  2. Set the dressing angle. Use IAE 1R18806 Setting piece 1 off, IAE 1R18807 Setting piece 1 off, IAE 1R18808 Setting piece 1 off, or IAE 1R18809 Setting piece 1 off. Refer to IAE 1R18700 Machine drawing 1 off for correct setting block.
  3. Attach the IAE 1R18421 Diamond dresser 1 off to the dressing attachment and safety with the set screw.
  4. Attach the IAE 1R18422 Support probe bracket 1 off to the grind attachment. Position the support probe bracket behind the dressing attachment and safety with the four set screws.
  5. Attach the IAE 1R18418 Multiflex holder 1 off at the locating slot on the support probe bracket and safety with the three set screws.
4. To measure the stage 7 to 11 stator vanes attach the IAE 1R18419 Probe holder 1 off at the multiflex holder interface and safety with the allen screw.
5. Install the HP compressor rear cases and vanes in to the machine.
6. Use the conditions given in machine requirements to machine the stage 7 to 11 stator vanes. Write a record of the dimensions which the stator vanes are machined to.
7. Use a Vacuum adjacent to the grinding wheel to remove the dust during the grinding process.
8. Remove the burrs from the stator vane tips and all unwanted material.
9. Measure the stator vane tip surface profile.
10. Remove the HP compressor rear cases and vanes and the turning fixture from the machine.
1. Refer to Figure, Figure, Figure, and Figure.
2. Install the HP compressor rear cases and vanes in the machine.
3. 1. Attach the IAE 1R18414 Boring bar 1 off to the machine tool post and safety with the three set screws.
  2. Attach the IAE 1R18418 Multiflex holder 1 off at the locating slot on the boring bar and safety with the three grub screws.
  3. Attach the IAE 1R18430 Turning holder 1 off to the multiflex holder interface and safety with the allen screw.
4. To measure the rotor path rings remove the turning holder and install the IAE 1R18419 Probe holder 1 off to the multiflex holder interface and safety with the allen screw.
5. Pre SBE 72-0343: Set and measure the swash and runout of the stage 7 and 12 rotor path rings. This must be a maximum of 0.003 in. (0.08 mm). Record the values.
6. SBE 72-0343: Set and measure the swash and runout of the stage 7 and 12 rotor path case assemblies. This must be a maximum of 0.003 in. (0.08 mm). Record the values.
7. Pre SBE 72-0343: Use the conditions given in machining requirements to machine the stage 7 to 12 rotor rings. Record the dimensions the rotor path rings are machined to.
8. SBE 72-0343: Use the conditions given in machining requirements to machine the stage 7 to 12 rotor case assemblies. Record the dimensions the rotor path rings are machined to.
9. NOTE
  Only remove the minimum quantity of abradable lining to show the metal of the rotor path at the front and rear of the liner.
  Use a Vacuum adjacent to the grinding wheel to remove unwanted material from accumulating during the grinding procedure.
10. Remove the unwanted material and the machine cusps after you have machined the rotor path rings.
11. Remove the HP compressor rear cases and vanes from the machine.
12. Put the HP compressor rear cases and vanes in to IAE 1R18415 Pallet 1 off.
1. Refer to Figure.
2. Use a correct hoist and lift the HP compressor rear cases and vanes from the pallet.
3. Align the turning fixture with the turnover stand adapter in the turnover stand.
4. Install the four bolts and four washers to attach the turning fixture to the turnover stand adapter. Tighten the four bolts.
5. Remove the bolts which attach the lifting beam to the turning fixture. Remove the hoist and the lifting beam.
6. Turn the assembly in the turnover stand from horizontal position to the vertical position.
7. Install the IAE 1R18416 Lifting tool 1 off.
8. Attach a correct hoist to the lifting tool. Hold the weight of the assembly on the hoist.
9. 1. Loosen the 12 nuts which safety the 12 location blocks on the turning fixture.
  2. Move the location blocks radially out.
  3. Remove the 10 nuts and 10 washers which attach the 10 clamps to the turning fixture.
  4. Remove the 10 clamps.
  5. Use the hoist installed in step H. and lift the HP compressor rear cases and vanes on to a clean work surface.
  6. Remove the hoist and the lifting tool from the HP compressor rear cases and vanes.
1. Use a Vacuum to remove any loose swarf or dust which may have accumulated during the grinding process.
2. Aqueous degrease the HP compressor rear case and vanes by TASK 70-11-03-300-503.
1. Refer to Figure.
2. Install the IAE 1R18212 Support ring 1 and the IAE 1R18417 Lifting Turnover trunnions 2 off, on the front support cone.
3. Attach the IAE 1R18431 Lifting beam 1 off on a correct hoist to the lifting turnover trunnions.
4. Lift the HP compressor rear cases and vanes.
5. Turn the HP compressor rear cases and vanes through 180 degrees. The support rings must point down.
6. Lower the HP compressor rear cases and vanes with the support ring on to a clean work surface.
7. Remove the lifting beam and the lifting turnover trunnions from the HP compressor rear cases and vanes.

View through the HP CompressorRear Cases and Vanes

Install the Clamping Tool

Install the Centralising Tool

Install the Lifting Turnover Trunnions

Prepare the Tools to Turn the HP Compressor Rear cases and Vanes

Install the HP Compressor Rear Cases and Vanes into the Turning Fixture

Move the HP Compressor Rear Cases and Vanesfrom the Turnover Stand to the Pallet

Machine the stator vane tips

Machine the Rotor Path Ring Liners

Pre SBE 72-0463: Machine the rotor path ring liners

Machine the rotor path ring liners

SBE 72-0463: Machine the rotor path ring liners

Requirements After Job Completion

Follow-On Conditions

NONE

Manufacturer Code:	0AM53
Enterprise Name:	IAE INTERNATIONAL AERO ENGINES AG
BU Name:	NULL
Building:	SUITE 400
Street:	628 HEBRON AVENUE
City:	GLASTONBURY
State:	CT
Zip Code:	06033
Country:	USA

Manufacturer Code:	LOCAL
Enterprise Name:	LOCALLY SUPPLIED

Manufacturer Code:	X333X
Enterprise Name:	REFER TO V2500 SB ENG-79-0108

Manufacturer Code:	LOCAL
Tool Number:	Grinding Machine
Tool Name:	Grinding Machine

TASK 72-41-20-440-006-A02 HPC Rear Cases And Vanes Assembly - Machine The Stage 7 Through 11 Stator Vane Tips And The Stage 7 Through 12 Rotor Path Ring Liners (Mechanical Clamping Tool Method), Assembly-006

Export Control

Copyright

Applicability

Common Information

TASK 72-41-20-440-006-A02 HPC Rear Cases And Vanes Assembly - Machine The Stage 7 Through 11 Stator Vane Tips And The Stage 7 Through 12 Rotor Path Ring Liners (Mechanical Clamping Tool Method), Assembly-006

General

Machining Requirements

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-41-20-440-296 Install the Clamping Tool for Rear Case HP Compressor Stages 7 to 11

CAUTION

CAUTION

NOTE

CAUTION

NOTE

SUBTASK 72-41-20-440-297 Install the Centralising Tool for rear Case HP Compressor Stages 7 to 11

CAUTION

CAUTION

CAUTION

WARNING

SUBTASK 72-41-20-440-229 Prepare the Tools to Turn the HP Compressor Rear Cases and Vanes from the Horizontal to the Vertical

SUBTASK 72-41-20-440-230 Install the HP Compressor Rear Cases and Vanes in the Turning Fixture

SUBTASK 72-41-20-440-231 Install the HP Compressor Rear Cases and Vanes in the Pallet

SUBTASK 72-41-20-324-056 Machine the Stage 7 to 11 Stator Vanes

SUBTASK 72-41-20-440-214 Machine the Stage 7 to 12 Rotor Path Rings and Rotor Path Case Assemblies

NOTE

SUBTASK 72-41-20-440-234 Prepare the HP Compressor Rear Cases and Vanes to be Cleaned

SUBTASK 72-41-20-110-056 Clean the HP Compressor Rear Cases and Vanes

SUBTASK 72-41-20-440-235 Install the HP Compressor Rear Cases and Vanes on to the Support Rings

Figure: View through the HP CompressorRear Cases and Vanes

View through the HP CompressorRear Cases and Vanes